Axminster-type carpet



June 14, 1960 H. A. REINHARDT 2,940,479

AXMINSTER-TYPE CARPET Filed oct. 2a, 1957 s sheets-sheet 1 i@ fd 0% .lune 14, 1960 i H. A. REINHARD-r 2,940,479

AXMINSTER-TYPE CARPET Filed Oct. 28, 1957 3 Sheets-Sheet 2 June 14, 1960 H. A. REINHARDT 2,940,479

AxMmsTER-TYPE CARPET Filed Oct. 28, 1957 3 Sheets-Sheet 3 pmi AXMlNSTER-TYPE CARPET Filed Oct. 2S, 1957, Ser. No. 692,814

9 Claims. (Cl. 139-401) The present invention relates to pile fabric floor coverings and more particularly to an improved pile fabric door covering'whch may be made on an Axminster-type loom.

The traditional Axminster carpet empioys a pile tutt cut from a pile yarn which is looped about a holding weft shot to form a generally V-shaped tuft having two legs which extend upwardly from the backing'at each side of the holding weft shot. The tuft legs at the base of the tuft are engaged between adjacent weft shots, as the fabric is beaten-up the weaving operation, so that the portion of the pile yarn looped about the holding weft is tightly compressed. As the tufts extend upwardly from the backing fabric they open up, or blossom out, that is, the individual bers composing the tuft spread apart, becoming more widely separatedat progressively greater distances above the backing fabric.'

Thus each tuft vleg assumes atriangular or upwardlyflaring shape, as seen in cross-section taken warpwise of the fabric.V The breadth in the warpwise direction of a Whole tuft comprising two legs would, in the absence of restraint by the tufts of adjoining rows, be greater than the distance between adjoining tuft rows. The result is that one leg of a tutt in one row leans against the adjacent leg of the tuft in the adjoining row. As seen in warpwise cross-section, the adjacent tufts of two adjoining rows assume the shape of a W, wherein the lower points of the W constitute the bases of the tufts, the legs of each tuft being spread apart and the top of the leg of one tuft being pressed against the top of the leg of the adjacent tuft more closely than it is pressed against itscompanion leg of the same tuft. This effect is illus trated, for example, by the vfabric shown in Fig. l of the Phoenix Patent No. 1,849,550. This effect results in an uneven or non-uniform distribution of pile ber at the pile face of the fabric, as, at the pile face, the adjacent legs of two adjoining rows are more tightly pressed together, with resultant intermingling of fibers, than are the two legs of any single row.

Since both legs of a given tuft must be of the same color and texture, and thus the pattern can only be determined by changes of color of an entire tuft, such intermingling of adjacent tuft leg fibers tends, where the ad- 'jacent tufts are of different pattern colors, to obscure the pattern outline, detracting from deniteness of pattern delineation.

An object of the invention isto provide a woven pile fabric oor covering, woven on an Axminster loom,

which has a more even and uniform distribution of pile liber in the `exposed pile lsurface than has .heretofore been possible of attainmentfin Axminster manufactm'e. '1- `.tmother object vvisfto provide an Axminster-type 'fabric construction which provides a sharper pattern delineation forjaL given pitch Vthan has heretofore been attainable'vin xAxminstercarpets. f f

Y further `object ofthe invention is'to provide an AXmnster-type fabric which affords a large savingin VUnited States Patent Patented June 2.1 pile material for a given degree of coverage ofthe fabric backing.

Another object 'is to provide an Axminster-type fabric construction which is more luxurious than heretofore known in Axminster-type fabric, in that it has a greater pile height.

The invention will be more fully understood from th accompanying drawings, wherein:

Fig. 1 is a diagrammatic perspective view, partly broken away, ofV typical 3-weft-plane fabric embodying my invention;` Y

Fig. 2 is a warpwise cross-section of a 2weft-plane Fig. 3-is a warpwise cross-section ofa single-weftplane fabric; i 1

Fig. 4 is a side elevation, somewhat schematic, ofa loom on which my method may be practiced forth manufacture of the fabric of my invention;

Figs. 5-9 inclusive are `schematic transverse vsections of the loom at the weaving point illustrating respectively successive steps of the method; and

Fig. l0 lis a diagrammatic warpwise sectional View ofra fabric similar to that of Fig.V l showing a modification.'

In accordance with the invention I provide an Axminster type woven pile fabric wherein the pile tuft instead of being V-shaped and looped about a holding weft shot as in the traditional Axminster, consists of a single leg only, the leg extending above the upper face of the backing and being securely bound in the backing by being passed between adjacent pairs of weft shots and turned at its lower end to underlie a weft shot. The wefts in my fabric, as in conventional Axminster fabric, are inserted in pairs by a needle and l employ the term weft shot herein to designate such a pair of simultaneouslyinserted wefts which function in the fabric construction as a single weft unit.

In order that the disclosure and description hereinafter of my method of manufacture of my fabric may be clearly understood l will first briefly describe the Axminster-type loom on which the method is practiced. Referring to Fig. 4 of the drawing, the loom frame comprises a pair of side frame members 2 joined by crossgirths (not shown). The main shaft 4 extending between the side frames 2 carries a series of cams which operate the various loom mechanisms in properly timed relationship. The binder warps 6 and stuifer warps 8 are supplied from a beam (not shown) from which they pass forwardly of the loom as shown to the weaving point or fell 4t) of the carpet. From the fell the woven carpet passes forwardly across the breast beam lo to a suitable take-up roll (not shown). Suitable heddles (not shown) are provided to shed the various warps.

The pile yarns are supplied from a series of ktube frames 14 carried on an overhead carrier chain 12. Each tube frame 14 has a row of small metal tubes 16 projecting therefrom, from each of which tubes one of the warp yarns 1S protrudes. Each tube frame is .taken `in turn from the carrier 12 by a pair of clutch arms 20 and lowered to the weaving point. At the weaving point the tube frame is rocked counterclockwise about a horizontallaxis by means of the rod 22, bell crank 24, rod 26, `cam follower 2S land a cam 30 on lmain Vshaft 4. .This rocking produces the so-called wipingbetween binder warps land -then'moved downwardly fand forwardly to carryl the 'pile yarn: ends 18 below the binder and stuffer warp's,` whereupon the tube VfratrieV and tubes are lifted, at the end of the `wiping-inaction, to clear the tubes from the 'warps, leaving ashort ,length of pile yarn extending'downwardly from thetube'apd between `the binder warps and stuifer warps.' -This 'liftcamon the main shaft 4 tofswing V"fing action of the 'frame isfeiec'tedby seglat'the'sam'e timerso that thewefts of the completed f abf ric are disposed in pairs. Y Y

-A comb 44'is mounted for a conventional put-out Y and put-.up movement by'whch, Vin the' case of the con- Y ventional VAxminister fabric, itengages the pile yarn ends 18 depending below the `warps',A to Vturn themupwardly wefts'62 had been inserted and beat-up. As appears inY Fig. 5, the upper weft pair 60 is disposed forwardlyY of the weft pair 62, that is, to the right in Fig. 5.

As the wiping-in action'continues, the tubes 16 rotate counter-clockwise (by rod 22 and cam 30, Fig. 4) and then are lifted (cam 32, Fig. 4) into the position-'in l which theyappearin Fig. 6 with the pile yarn ends 18 extending between and slightly below the warps and lyingagainst the weft pair 62. As the tuft isto have only one leg, the yarnend 18 need extend downwardly only -1 suiciently to provide the length of yarn which is tobe yarn to be bound into the fabric, but not suicient to provide a second leg on the tuft, is accomplished by appropriate adjustment of 'the cam segment 32, having regard to .the other.Y adjustments of the loom, as will be' readily understood by those skilledin' the art.

.A tfthis point, as appears in Fig. 6,` `a pair of holding wefts Y64 are inerted in the shed by the needle and then 'into the fell it moves into a position. above the pair of I of the pile and I holdingrweft 64 to formrthe second piletuftleg. This put'up and lies against the f l1`140of' thefcloth. Neces- 10 sarily, any extent of pilergyarp rearwardly .of the holding weftsl64`will beturnedfupwardly by Vthe combV to extend v toward the upper surface of tbefbackingQrslightlythereabove. The tube frame k14 how receives its upward, draw-oli about tbelast-inserted holding weftshotY to form thefsec- 15 movement, movingwinto-thepositionshown in Fig. 8 to ff ond pileI tuftleg; :While Vthe comb 4 4 is dwelling'in its leave extending from the tubes 16 =a length of yarn suff up position and engaging the fell Yof the-carpet,the cient to provide the first tuft leg 66-of the which -tube Vframe 2141 isfgiven V-an upwardV movefnent bythe has just been formed, and, in addition,Y to provide an end Y' Ydraw-olf cam segment 50 on the cam disc"34 to ldraw 18 to protrude from the tube for usemtforming the next :"additio'n'al pile yarn from the? spools on-the frame to 20tl1ft i0 be' formed by hatubi 'U16-Comb 2&11 .iles

jprovide the-protruding ends 18`for the nextv row of tufts against the fell of the clothldurmg this drawotf'mouon Y to be formed bythat tube frame. of the ltube frame is useful 1ntending to prevent shp- J f' Thereafter, the pile yarn is severed atth'e fdesired VVPage 0f thePile Yam between the WeffS V64 and 62 111'- fheight above the cloth backing by knives 46, 48. Finalf ing draw-OE. l i J ly, the tube frame is raised by the clutch arms 20 and 25 The pile yarn 1S then Cui, Flg- Q, by 'd le Cutflflsv, 48,

l:re-attached to the carrier chain 12, which'then advances leaving the VIIW1Y formed ftuft W1th a Slngl'plk 18566 Vto bring the next tube frame'14 into position to be en- Of tile desired helghtralld leaVmg i116 YalllllY 1312mngaged bythe clutcha'rms as'the cycle is repeated to l'fl'lldlllg fl'Om the tube 16 Y e Y Y form the next row of the next mwfof tufts, Y Thereafter another panof upper wefts k601s inserted Turning now to Figs. 5, 6, 7, Sand 9, the details of 3072111@ the CYCle repeated 1 i Y my' method of making the fabric of the invention will -S dl'aW'O movement thuberm *needfnot be be described. In Fig. 5 the tube frame 14 has 'been 'raised aS `fll above the line Vof action :of b1 ades46r43 lowered from the carrier chain 12 and the'tubes 16 with aS i't must be raised the conventional Axr'mnster manuthe protruding yarn tufts 18 have been inserted between factlll'e, as ih@ amount Of'yanl -WhlCh mim 'be' lef'PIO- the warps at the Vbeginning'of thewiping-iniaction The 35 tfudmg as an end '18 1S`0D1Y`hl`fequlfed t0 folmfa reed 3s .at this nmeisin its rearwardpdsifiou." Pre- Smale-legged tuft, v:is `contrasted v vlth atwcglegsedtuft. `vious to this stage the pair of' upper wefts 60 hadfbeen Thl departure from the ConventionalAxnnnster metlr'v inserted andbeat-upvand, rhereafteathe pair of'inding 0d 1S 'taken Care `vf'bv approprlate adiustment ofthe camv segment 50, having regard to-the other adjustments of the loom including the 'adjustment` of the -cam 32, as will be readily'understoodV by those skilled 1iny theart..

From time to timethe binder warps 6 and the stuler fwarps 8 are shedded bythe heddles in the'conventional manner, as will be well understood. Y

' Although only a single ytuft 66 has been referred toin the foregoing description, it will be understood that each tube framev 14 ycarries arow offtubes `16, perpendicular 1 to the paper of the drawingandthat accordinglyga weft- Wise row of tufts like tuft 66 is formedsimultaneously bound imo the baekin vfd hold the .ruft in place, in con- 5o f them/1th trast to the usual Aigrminster procedure inY which the Tile 'resll't 2f m15 medmd Pf Wcavmg 1S the fabn f yarn must extend enough'lower, than in my method,` to my llnvenuon luusffa'd lm 'Flgs- 1 2 and 3; -Rifen'mg provide a second legfor the same ruft. VThe proper to Fig; 1 the fabnqmpnse-"S (.1) the backmg Structure height or vertical position of the tube frame 14 at the made u? of Wefts bmdef WarPs andtWo Planes of Sniffer end of the wiping-in action to provide suicient tuft Warps mdloated genefauyrafs and (2) 'the P11e face composed of pile tufts indicated generally at 70. :Each pile stuft consists of a single leg 66 extending uprightly i beat-up by a forward v,movement of the reed 38 into the positionY shown in Fig.Y 7. As the weft pair 64 Vis beaten be tightly engaged by the holding weft pair .'64 and the binding weft pair 62 therebelow. The upper Wefts 60,

.inn pairs, are bound down againstVV the stuier warps 74 of fthe upper plane vof stuerwarps by the Ybinder-'warps 76 Vwhich pass above the Wefts 60.V Whenfthewefts 60 Vhave been inserted .the shed is changed 'to bring Vthe' binder Vtiirn "about the i Y Y s the, pair oholding wefts 64 andgthepair of--binding v'veits,v

warp 76down soth'at'the next pairofwefts,which"is the of bindingwefts '62,*:is placed above the fbinderwarprl. :,Theistuer warps likewise are appropriately sheddedso that'f-theilbinding .Weftsi 62 fare belowl'lothV binding wefts 62, causing the' lower endtof the pile yarn to-be bent asshown in jFig. 7 yanddisp'osed between 6 2. @The pile yarn'abovcis'drivenfforwardly'intoenj Y i gag'ement with the pair of'upperfS-weftsi. 60.Y The reed. 1 PllleSg-Of StuBrWarPS and 31 holdiiglefwafe be? V.then moves backwardlyinto itsjdotted line position of Wllthe Planesof Stuferrwarpsr' ','Wheuweftsfwgf Fig. 'l 1 Y Y j; .A 'and' 164 haveibeenjplaced thefshedili'snagainzchangedso V'In normal Axminstermanufacture when the reed138 is that the next pair of upper Wefts 60 isidisposedfabovee returned to its dotted positionof Fig. 7the comb 44' upperplaneof stuler 'warps and belowfthe binderwarp ,would'be put outand put up to engage the extending 75 76. V 5 a 1 Axminster, as tuft legs of different colors are never pressed together more strongly, with intermingling of bers, than are tuft legs of the same-color, as 'occurs .-in vconventional Axminster.

A further advantage of my method and product is that the pile height may be considerably higher than .is .possible with the ordinary Axminster method and product, other factors .remaining the same. .In the ordinary .Axminster construction the height of the pile is limited :by the length of pile yarn 18 which may be allowed Vto :protrude from the tubes ,16. If this protruding end 18 .is too long, ,it is impossible to Wipe-in the tubes and yarns, as the yarns hang up on the warps. For this reason, in Axminster weaving, the yarn ends 18 vcannot exceed a predetermined maximum length. With my method, this maximum length of yarn 18 will provide a pile tuft considerably higher than that possible with theconventional '.Axminster method, inasmuch as the length 18 in .my

method does not provide a tuft leg but only the length required to be bound-in between the wefts 64, 62. In fntrast, in the conventional .Axminster method this length 18 must lprovide the yarn `for both the .length which is bound in Vand one of the tuft legs.

By the employment of pile :of increased height, the `warpwise spacing between rows may Vbe increased while with consequent saving `of :expensive pile yarn. Also, .with increased pile height, the fabric maybe designed with many outs or missing tufts vwithout impairing the coverage of the backing. Such reduction in the number of tufts `per square inch which my invention maires posi# sible provides further possibility of savings in the expensive pile yarn.

My invention is not 4limited to 4the construction shown for ypurposes of illustration in Fig. l. The vinvention maybe applied to any kind .of .Axminster construction.

lIt also may be applied in the form of 2-shot1or .l-shot fabrics.

Referring to Fig. 2, a 2-shot fabric is illustrated wherein the wefts are arranged in two planes, one above and one below the stufter warps 78. The pairs of upper or holding wefts 84, 86 are bound down against the stuifer warps and the pairs of lower or binding wefts 88, 90 are bound up against the stutter warps by the pairs of binder warps 80, 82 which pass alternately above weft pairs in the upper plane and below weft pairs in the lower plane. The wiping-in action occurs following the insertion of a binding weft pair 88, 90 whereupon an upper or holding weft pair 84, 86 is inserted and when beaten-up bends the pile yarns to cause the lower ends to be turned at an inclination to lie between and be engaged by a binding weft pair 88, 90 and a holding weft pair 84, 86, leaving the greater part of the tuft 66 extending upwardly between adjacent pairs of holding wefts 84, 86 to provide a single tuft leg.

A' 1shot construction is illustrated in Fig. 3 wherein there are no stuifer warps and the wefts 92, 94 are in pairs lying in a single plane. One set of binder warps 96 passes over alternate pairs of weft shots and under the intermediate pairs of weft shots and the other set of binder warps 98 passes under said alternate weft shots and over said intermediate weft shots. The pile yarns are wiped-in as described above and wiping-in is followed by the insertion of a pair of wefts which are beaten-up to engage the pile yarn between that pair and the preceding weft pair so that the tuft has a single leg 66 extended upwardly between adjacent pairs of wefts. Since there iS .obtaining the same degree of coverage of the backing V6 a single plane .only of .wefts the lower ends lllZ of Athe pile yarns .are not turned by means of the insertion of a weft pair. When the .fabric "has "been woven, .it `is back-coated with an adhesive composition 1D0, as by coating with a doctor blade, so that the flower ends of the pile yarns which extend "between .the weftpairs' are turned to lie against the .back of -the backing and securely united thereto 'by the adhesive. Each .tut comprises a single Yleg 66 .extending uprightly between adjacent weft pairs and having Lits lower end .turned at .annclination to .lie beneath one of .said adjacent weft pairs. .As .'in the other .described embodiment of the invention, the pile liber at the exposed pileface's uniformly distributed.

Other variations of the fabric -of the invention, e.g., those of Figs. l .and.2,.may 'be 'back-coated with an adhesive, .if desired, or as required :to .give the degree of tuft bind desired, asis well understood in theart.

.It will be .appreciated that .the lower .ends of the pile tufts 66 need not be so short -as to terminate immediately after they .havepassed .across .the (bottom .of .the holding weft pair but maybe somewhat .longer .and may be turned upwardly around 'the .holding weft pair, .as `the traditional Axminster tuft, to extend .toward .the upper surface of the .backing or to extend between .the v.wefts ofthe upper plane or toextend .above vthe .upper .surface of the backing, vas .is .illustrated by the .tuft 66 of Fig. .10. Such constructions, while they .consume .more pile yarn than my presently preferred embodiment `illustrated `in the drawing, nevertheless provide the .suhstantiallbeneiits of the invention.

Other and .further Vembodiments of the invention and modificationsV of .theparticular fabric .constructions which have been describedin detail. to .illustrate the application of my invention maybe made by rfhoseskilled .in `t'heart without departing from the spirit and scope .of the 'in- -vent'ion .and the following claims .are .intended to .em-

I claim: Y

l. A woven pile fabric floor covering .comprising a series of wefts disposed in pairs, a series 'of binder warps interwoven with the wefts to extend between 'and `alternately above and below pairs of wefts and hold the wefts in 'place to form a backing, Yand a =pile face comprising equally-spaced rows of pile tufts bound in said backing, each tuft consisting of a single leg extending upwardly between adjacent pairs of wefts and having its lower end turned at an inclination to underlie one of said adjacent pairs of wefts.

2. A woven pile fabric floor covering comprising aA series of wefts disposed in pairs and arranged in three planes, stuifer warps extending transversely of the wefts between the upper and middle planes of wefts and between the middle and lower planes of wefts, binder warps interwoven with the wefts to extend alternately above weft pairs in the upper plane and below weft pairs in the lower plane to securely bind together said wefts and Studer warps and hold them in .place to form a backing, and a pile face comprising equally-spaced rows of pile tufts bound in said backing, each tuft consisting of a single leg extending upwardly between adjacent pairs of wefts and having its lower end turned at an inclination to lie between and be bound in position by weft pairs in different planes.

3. A woven pile fabric floor covering comprising a series of wefts disposed in pairs and arranged in three planes, stuier warps extending transversely of the wefts between the upper and middle planes of wefts and between the middle and lower planes of wefts, binder warps interwoven with the wefts to extend alternately above weft pairs in the upper plane and below weft pairs in the lower plane to securely bind together said wefts and stuler warps and hold them in place to ltorm a backing, and a 7 s pile face comprising equally-spaced rows of pile tufts "boundinrsaid backing; each tuft consisting ofa single "leg Vextending upwardly between adjacent pairs of wefts in said upper plane and' having its lower end turned at an inclination to lie between and be bound in position by 1 apairrof wefts in the middle plane and a pair of wefts fj in ythe'lower plane.

1 4. "A woven pile'fabric oor covering comprising a j series Vof wefts disposed in pairs and Aarranged in an upper planeand in a lower plane, stufier warps extending transversely of the wefts between the planes of wefts; binder warpslinterwoven with the wefts to extend Y, alternately above vweft pairs inthe upper plane and below weit pairs the lower plane to securely bindV together said wefts and sniffer warps and hold them in place to form aback- 1 ing, and a pile face comprising equally-spaced vrows ofpile bound injsaid backing, each'tuft consisting of ai single leg extending upwardly between adjacent pairs Y tufts interwoven withY said weft pairs to form 'a pile face, each tuftconsisting of a single leg extending upwardly .between adjacent weft pairs `and having its lower end nately above weft pairsin the upper plane and below weft pairsrin the lower plane to securely bind together said wefts and'stuffer warps and hold them in place torform j a backing, and a pile face comprising equally-spaced rows of'pile tufts bound in said'backing, each tuft consisting Vof asingle leg extending upwardly between vadjacent pairsA i of 'weftsin' said upper planeV and Yhaving its lowerV end j turned at 'an inclination` to'flie between and-be bound in position by a pair of weftslin thelower planeV and one of v Vsaidadjacent pairs of wefts in the upper plane. 6. A woven pile fabric iloorV covering comprising a f series of wefts disposed in'pairs and arranged in a; single plane, binder warps interwoven with the wefts to ex-f tend above'alternate weft pairs and belowv the intermediate f weft pairs, other binder warps interwoven with the wefts to extend below said alternate weft pairs and above saidl intermediate weft pairs to securely bind together said wefts and hold them in .place to form a backing, and a pile face comprising equally-spaced rows of pile tufts bound in said backing, each tuft consisting of a single leg ex- Y 7. A woven pile fabric floor covering comprising a serie'sof wefts disposed in pairs and arranged in a single plane binder warps` interwoven with Vthe wefts to extend abovealternate weft pairs and below the intermediatefweft pairs,7binder warps interwoven with the wefts to extend vbelow said alternate weft pairs and above said 'intermediate weft pairsV to securely bind together said l"wefts and hold them -in place to vform a backing, a pile uface comprising equally-spacedrows of pile tufts bound l-in said backing, each tuft consisting of a single leg extending upwardly between adjacent kpairs of .wefts and having its/lowerend'turned atan inclination to underlie one of `said adjacent pairs of wefts, and an adhesive coatin'gfon lthe underv surface of said backing securely anchoring said lo'wer Vendsto said backing.

8. A` pile'ffabricoor covering of the Axminster type Iwhichcom'prisesa series of wefts disposedrin pairs interwovennwithjaV series of binder warps so that the warps "extend between and alternately above and below weft pairs t'hold theni in place to form abacliing, and pile turned at aninclination to underlie one of'said adjacent Weft pairs.j I I?. Y rV y. l9. A woven Vpile fabric' oor covcring comprising'.;a

' series of wefts disposed in-pairs,ra series of binder warps Y'interwoven with the wefts to extend between'and laltertween adjacent pairs of wefts and havingv its :lower end .turned Vat .aninclinationto extend beneath one 'of said :adjacent pairs of wefts and turn upwardly at the opposite side thereof and extendl between that weft: andthe Vacljoining weft but not suiciently abovethe vbacking of the Vlloortcovering to constitute a tuft leg.

vReferences 1Cited inthe le of this patent UNITED STATES .PATENTS Itending'upwardly between adjacent pairs of wefts and havingrits lower end turned at an inclination to'underlie one of said adjacent pairs of wefts.

2,783,776 Lyle f Mar. 5,1957

UNITED STATES PATENT OFFICE CERTIFICATE oF CORRECTION Patent No. 2,940,479 June 14, 1960 Henry A. Reinhardt It is hereby certified that error appears in the above numbered patent requiring correction and that. the said Letters Patent should read as corrected below,7

In the grant, lines 2 and l2, vand in the heading to the printed specification, line 4, name of assignee, for "Bigelow- Sanford Carpet Company, Inc.", each occurrence, read Bigelow- Sanford, Inc.

Signed and sealed this 15th day of November 1960,a

(SEAL) Attest:

KARL H AXLINE l ROBERT C. wMrsoN ttesbing 'Officier i Conmissioner of Patents' 

